Kuliah Kapita Selekta Teknik Elektro Institut Teknologi Indonesia … · 2020. 7. 5. · Pengenalan umum mengenai sistem otomasi industri terkait sistem instrumentasi, kontrol dan

Implementasi Sistem Otomasi dalam Industri

Kuliah Kapita Selekta

Teknik Elektro – Institut Teknologi Indonesia

Sabtu - 13 Juni 2020

2©2020 PT. Genta Raya Cemerlang

Perkenalan

Anthony Josia

[email protected]

0811875218

@anthonyjosia

Pendidikan & Pengalaman Kerja:

Teknik Elektro – Institut Teknologi Indonesia (1992 - 1998)

PT. Kota Minyak Automation (1998 – 2001)

PT. Schneider Indonesia (2001 – 2005)

GEIOC - GE Intelligent Platforms (2005 – 2010)

PT. Tiara Prima Solusi (2010 – 2012)

PT. Genta Raya Cemerlang (2012 – sekarang)

Skill & Kompetensi:

Automation & Control System: PLC & HMI/SCADA

Network

Basic Instrumentation

Software Application & Database

Aplikasi:

Auxiliary and Engine Control, Boiler Control, Well Test, Gathering Station, Water Injection System, Electrical Transmission,

Gas Facilities, Gas Metering System, Integrated Office System, Remote Monitoring System, Building Automation System, Ash

Handling/Coal Handling System, Continuous Emission Monitoring System, Water/Waste Water Treatment Plant

Industri:

Oil & Gas, Palm Oil, Power, Food & Beverages, Pharma, Pulp & Paper, Mining



Latar Belakang:

Kemajuan teknologi instrumentasi, kontrol dan IT telah membawa perubahan besar

dalam berbagai sektor industri dan saat ini telah mengarah pada sistem otomasi

terintegrasi yang secara umum sering disebut Industri 4.0.

Tujuan:

Sharing session dengan mahasiswa Teknik Elektro ITI untuk berbagi pengalaman

dan pandangan terkait topik ini, supaya engineer Teknik Elektro ITI memiliki

semangat untuk terus berkreasi, berinovasi dan melengkapi diri dengan kompetensi

teknologi yang up to date.



Abstrak:

Pengenalan umum mengenai sistem otomasi industri terkait sistem instrumentasi,

kontrol dan IT.

Pembahasan secara umum sistem kontrol berbasis PLC (Programmable Logic

Controller) dan DCS (Distributed Control System), HMI/SCADA (Human Machine

Interface / Supervisory Control & Data Acquisition), serta berbagai protokol

komunikasi industri dan integrasi dengan sistem IT, baik secara hardware maupun

software dengan beberapa contoh nyata dari aplikasi industri.

Sebagai penutup terbuka sesi interaktif untuk diskusi dan tanya jawab seputar topik

dan pengalaman lapangan.


Industrial Automation System

As an integrated system, the entire industrial automation system is built of the

following components:

Instrumentation System

Collection of instruments used to measure, monitor, and control a process.

Control System

Manages, commands, directs, or regulates the behavior of other devices

or systems using control loops.

Communication System

Collection of communications equipment that is integrated to link


Objective of Industrial Automation System

1. Protect People

2. Protect Environment

3. Protect Equipment

4. Maintain Smooth Operation

5. Achieve Product Rates & Quality

6. Optimizing First Five Above = Profit

7. Monitoring, Analysis & Diagnostic


Automation System Components

HMI

Controller

SCADA Server

Remote Monitoring

OUTPUT

INPUT

Gas Turbine


Control System

Communication System

Control

Network

Corporate

Network

Client


Inputs Devices • Switches and Pushbuttons

• Sensing Devices

• Limit Switches

• Photoelectric Sensors

• Proximity Sensors

• Condition Sensors

• Pressure

• Level

• Temperature

• Flow

•Vacuum Switches

• Float Switches

• Encoders

• Valves

• Motor Starters

• Solenoids

• Actuators

• Control Relays

• Horns & Alarms

• Stack Lights

• Fans

• Counter/Totalizer

• Pumps

• Printers

Outputs Devices


• Instrumentation system consist of measuring devices, sensor and actuator which serve as an

input or output of control system

https://www.google.co.id/url?q=http://anekajayatehnik.indonetwork.co.id/2520324/jual-and-beli-explosion-proof-start-stop-push-button.htm&sa=U&ei=GgpaVb2fDJOTuATUzoDACw&ved=0CBQQ9QEwAA&usg=AFQjCNEdyvZTDUj2DktbOANpurE1ywXO3Q


Instrumentation Symbol


Process Flow Diagram

Process flow diagram is a simple illustration that uses process symbols to

describe the primary flow path through a unit


Piping & Instrumentation Diagram (P&ID)

A process and instrument drawing is more complex, it includes a graphic

representation of the equipment, piping, and instrumentation


Control System

A control system is a system of devices that manages, commands, directs or regulates the behavior

of other devices or systems using control loops.

A control loop is the fundamental building block of industrial control systems. It consists of all the

physical components and control functions necessary to automatically adjust the value of a measured

process variable (PV) to equal the value of a desired set-point (SP). It includes the process sensor,

the controller function, and the final control element (FCE) which are all required for automatic

control.


Programmable Logic Controller (PLC)

• Programmable Logic Controller (PLC) is a computer-type device used to control equipment inan industrial facility. It accepts inputs from switches and sensors, evaluates these inaccordance with a stored program, and generates outputs to control machines and processes.

• Programmable Logic Controller (PLC) were created to replace conventional relay controls with

solid state equipment.

Typical PLC Components

4. I/O Modules

3. CPU with embedded

Comm. Module

2. Power Supply

Digital, Analog,Thermocouple,

RTD, Hi Speed Counter, etc

1. Rack 5. Comm. Module 6. Programming Tools

7. Programming Cable




PLC Cycle

Housekeeping

Input Scan

Program

Execution

Output Scan

Comm. Service

Diagnostics

Sc

an

tim

e o

f P

LC


During each operating cycle, the processor reads all inputs, takes these values, and

energizes or de-energizes the outputs according to the user program. This process is

known as a scan

The scan time indicates how fast the controller can react to changes in inputs. Scan

times vary with computer model and program content, and length. If a controller has to

react to an input signal that changes states twice during the scan time, it is possible that

the PLC will never be able to detect this change.


1M

T R1

WARNING HORN

W ARNING DELAY

5 SE C

1M 1

M O TO R STAR TER

H Y D R A U LIC PU M P

PB2

START MOTORSPB1

MASTER STOP

FLS-1PS-1

TR1


Typical Motor Control Circuit


Relational Diagram Of Field I/O & Ladder Logic

1 2MODULE

INPUT

3

1M

4MODULEOUTPUT


I1 I2 I3 I45s Q2

TIMER

R1Q2Q1

PB1 PB2 FLS-1 PS-1M1_RUN

M1_HORN

M1_RUN

I1 = PB1I2 = PB2I3 = FLS-1I4 = PS-1

Q1 = M1_HORNQ2 = M1_RUN


Sensor & Signal for Process Control

Analog Input

4-20 mA

Pressure Transmitter PLC

Measurement range

0 – 10 BarAnalog Input Register

0 – 32767Analog Input wiring example


IEC 61131-3 Programming Language


Sequential Function Chart

Ladder Diagram

Function Block Diagram

Instruction ListStructure Text


HMI / SCADA

What is the difference between HMI and SCADA?

The main difference between HMI and SCADA is their scope. HMI is actually just a part of the

SCADA system.

HMI = Human Machine Interface

HMI functionality: Visualizing the Process

SCADA = Supervisory Control And Data Acquisition

SCADA functionality: Managing and Controlling the Process

HMI could be only a small touchscreen mounted on the panel or even an annunciator or simple

flow process diagram with numbers of indicator lamps


HMI / SCADA

Supervisory control and data acquisition (SCADA) is a system of software and hardware elements

that widely used in various industry to help operator to monitor and control the process in real-time

locally or even at remote location.

SCADA system allows the operator to get direct interaction with the devices, such as sensors,

valves, pumps, motors, etc. through the HMI (Human Machine Interface) visualization. SCADA

system also have historical data for further analysis.


HMI Screen

Point Database

HMI Driver

Nati

ve

OP

C

OPC

Devices

Ports

Industrial Controllers

Industrial

Protocols

Points

Screens Alarms Scripts Trends

HMI / SCADA

HMI/SCADA

PLC


Distributed Control System (DCS)

DCS systems have for many years provided multi-disciplined controllers for logic, sequential and

process control, HMIs, custom applications, and business integration on one platform.

Although PLCs have become more powerful, they are still based on “loose” component architectures

allowing functions to be easily added with hardware and software. For example, a historian may be

added to many PLC products by plugging a module into the backplane that acquires data from the

controllers, but history communications is done over a separate Ethernet connection.


Distributed Control System (DCS)


Industrial Communication Protocols

There are many Industrial Communication Protocols was developed, some protocols was

proprietary in earlier time, some protocols was for specific application such as for Building

Automation, Lighting Control, HVAC, etc.

Some of protocols widely used:

Modbus (RTU / TCP / UDP)

Profibus PA / DP

Profinet

Devicenet

HART … and.. still many more….



Modbus is a serial communications protocol originally published by Modicon in 1979 for use with its PLC.

Simple and robust, it has since become a de facto standard communication protocol, and it is now a

commonly available means of connecting industrial electronic devices.

The main reasons for the use of Modbus in the industrial environment are:

developed with industrial applications in mind

openly published and royalty-free

easy to deploy and maintain

moves raw bits or words without placing many restrictions on vendors

Modbus enables communication among many (approximately 240) devices connected to the same network

The development and update of Modbus protocols has been managed by the Modbus Organization since

April 2004, when Schneider Electric transferred rights to that organization. The Modbus Organization is an

association of users and suppliers of Modbus compliant devices that seeks to drive the adoption and

evolution of Modbus.

http://www.modbus.org


Modbus is the simplest protocol that widely used because no need special cable, no need

additional communication card or converter, and available in serial and ethernet

There are many Modbus tester software available in market and many devices have built-in

Modbus protocol for integration with other devices.


http://www.modbus.org



PROFIBUS (acronym for Process Field Bus) is a standard for fieldbus communication in

automation technology and was first promoted in 1989 by BMBF (German department of

education and research) and then used by Siemens. It should not be confused with the

PROFINET standard for Industrial Ethernet.

PROFINET (acronym for Process Field Net) is an industry technical standard for data

communication over Industrial Ethernet, designed for collecting data from, and controlling,

equipment in industrial systems, with a particular strength in delivering data under tight time

constraints (on the order of 1ms or less).https://www.profibus.com/technology/profinet/

https://www.profibus.com/technology/profibus/


Industrial Communication Protocolshttps://opcfoundation.org/

OPC (Open Platform Communications) is a software interface standard that allows Windows programs to

communicate with industrial hardware devices.

OPC is implemented in server/client pairs. The OPC server is a software program that converts the hardware

communication protocol used by a PLC into the OPC protocol. The OPC client software is any program that

needs to connect to the hardware, such as an HMI. The OPC client uses the OPC server to get data from or

send commands to the hardware.

https://opcdatahub.com/WhatIsOPC.html


Introduction to Industrial Communication

Field

PLC DCS CNC Robot

Control

Information


Sequencer

GE Fanuc 90-70

Operator Workstation

Woodward

Atlas PCVibration Monitor

BN3500

VersaMax I/O

Genius Bus

Typical Configuration – GE LM2000

Ethernet


Ethernet

Typical Configuration – GE TM2500 GEN8

Woodward Servo

Position Controller

VSV SPC

Slave ID 2

CDP SPC

Slave ID 3192.168.15.x

VersaMax IO

CAN Open

Devicenet

DVP DVP

192.168.15.1

BN3500 –

Vibration

AVR DMMF

niu1.gcp

192.168.0.2

niu2.gcp

192.168.0.3

niu3.tcp

192.168.0.4

niu4.mgtb

192.168.0.5

niu5.mgtb

192.168.0.6

niu6.tcp

192.168.0.7

niu7.tcp

192.168.0.8

niu8.tcp

192.168.0.9

HMI/SCADA

Cimplicity

HMI/SCADA

Cimplicity

192.168.15.x 192.168.15.x

RX3i –Sequencer


Typical Configuration – Gas Compressor Station

EWS-01OWS-01 OWS-02

ESD FGSPCS IS PCS NIS

Metering System

GTCP A GTCP B

Serial to FO

Converter

F&G

F&G

To existing SCADA

ProLinx ProLinx

EWS-02

LAN A

ICS Triplex / Rockwell Automation

Solar Turbine - Rockwell Automation

GE Bently Nevada

MTL / GE Intelligent Platforms

GEG-A

Power MeterGEG-B

Power MeterDEG

Power Meter

Vibration


Typical Configuration – Gas Metering Station

Siemens S7-300

Operator StationEngineering Station

Omni FlowCom

Gas Chromatograph

Controller Unit

Daniel 2350

RS-485

Ethernet


Typical Configuration – Sub Station Automation

Engineering Station

Modbus / IEC 61850

Bay Controller IED Bay Controller IED

IEC104

Operator Station

SCADA Master

DCC

Control Room

Switch YardIED IED PLC


Typical Configuration – SCADA Distribusi

GI DCC


Typical Configuration – Refinery Plant

Operator Workstation Weighing System Engineering Workstation

GE RX3i AB SLC500

Production

Report ServerOperator Workstation

Chronos SpeedAC

Weighing Controller

Serial Device Server

Corporate

Client

Control


Siemens

Ethernet

System Configuration – Fraksinasi Plant

Siemens S7-300

CPU 317-2 PN/DP

Operator WorkstationOperator Workstation

Profibus

IM 153

IM 361 IM 361 IM 361IM 360


Ethernet

Typical Configuration – Margarine Plant

RX3i

Engineering WorkstationOperator Workstation

Profibus Slaves 1 2 3 4 5

Danfoss

Drive

Danfoss

Soft Starter

Festo Beckhoff I/OMettler Toledo

Weighing


Typical Configuration – Power & Energy Monitoring

Power Monitoring Server

• Energy Usage Monitoring

• Power Quality Monitoring

Power Monitoring

Network

Corporate Network

Internet

Gateway

Remote

Web Client

RS-485 Network

Basic Metering

Intermediate Metering

Advanced Metering

Ethernet

Gateway

Basic Metering

RS-485 Network


Typical Configuration – CEMS Online

KLHK Office

SISPEK Server

Unit Pembangkitan

CEMS Shelter

Via Corporate /

3rd Party Provider

Opacity

Durag D‐R290 /

Horiba EM‐D5100

Flowmeter

Durag D‐FL100

Stack Gas Analyzer

ENDA‐5610

NOx

SO2

CO

O2

Opacity

Flow

Temperature

Opacity

Durag D‐R290 /

Horiba EM‐D5100

Flowmeter

Durag D‐FL100

Stack Gas Analyzer

ENDA‐5610

NOx

SO2

CO

O2

Opacity

Flow

Temperature

Stack #1

Stack #2

PGS

Data Logger

PGS DAS


Typical Configuration – CEMS Online

4-20mA

Gas Analyzer

4-20mA

Opacity

Opasity

Particulate

Flow Gas

Stack

NOx

SO2

CO

CO2

O2

DCS

HORIBA

ENDA 5000

Analog

Splitter

MCR-FL-C-UI-2UI-DCI-NC

4-20mA

Gas Analyzer

4-20mA

OpacityOpasity

Particulate

Flow Gas

Stack

NOx

SO2

CO

CO2

O2

DCS

HORIBA

ENDA 5000

Analog

Splitter

MCR-FL-C-UI-2UI-DCI-NC

CEMS Server

HRSG #2.1 HRSG #2.2

DAS


Typical Configuration – AQMS Mobile Station

BPPT

*Internet Ready

Ethernet

Data Logger

- Dashboard

- Trend, Report

- Alarm & Event

Parameters:

PM10

PM2.5

SO2

NO2

O3

CO

Mobile Station

*Internet via GSM modem

Server

Workstation

60” LED Smart TV

Client Workstation & Display

- Dashboard

- Trend, Report

- Alarm & Event

Panel PC

Analyzer


KLHK

Server SPARING

Via 3rd Party

Internet Provider

Typical Configuration – IPAL Online

OPSA 150

Systea Ammonia

Flowmeter

HP200 pH meter

pH

COD

NH3-N

Debit

Temp.

4-20mA Data Logger A

IPAL

Server

Control RoomShelter


Ethernet

Plant Monitoring & Performance Analysis

OWS #1 OWS #2

Remote

Access

Server

Vibration Monitor

BN 3500

Vibration Monitor

BN 3500

OWS #3 OWS #4

Arcnet

RTU #2

RTU#22

FT-110

Sequencer

&

Fuel Control

RTU #1

RTU#11

FT-110

Sequencer

&

Fuel Control

Ethernet

Remote

Access

Server

Vibration Monitor

BN 3500

Vibration Monitor

BN 3500

Arcnet

RTU #4

RTU#42

FT-110

Sequencer

&

Fuel Control

RTU #3

RTU#31

FT-110

Sequencer

&

Fuel Control

Cloud

Gateway

Server

Web Apps Client

- Dashboard

- Trending

- Report

- Alarm Notification

Unit 1-2

Unit 3-4

Office

FO

Converter


Aplikasi Terintegrasi berbasis Cloud

Server Cloud

Aplikasi Mobile

Server Lokal

Aplikasi Web

Sensor / AnalyzerCCTV


Industry 4.0

Industry 4.0 is a name for the current trend of automation and data exchange in

manufacturing technologies. It includes cyber-physical systems, the Internet of

things, cloud computing and cognitive computing. Industry 4.0 is commonly

referred to as the fourth industrial revolution.


Internet of Things

Internet of Things (IoT) is the network of

physical devices, vehicles, home appliances,

and other items embedded

with electronics, software, sensors, actuators,

and connectivity which enables these things

to connect and exchange data, creating

opportunities for more direct integration of the

physical world into computer-based systems,

resulting in efficiency improvements,

economic benefits, and reduced human

exertions.


Cloud Computing

Cloud computing is an information

technology (IT) paradigm that enables ubiquitous

access to shared pools of configurable system

resources and higher-level services that can be

rapidly provisioned with minimal management

effort, often over the Internet. Cloud computing

relies on sharing of resources to achieve

coherence and economies of scale, similar to

a public utility.


Cognitive Computing

Cognitive computing is the simulation of human thought processes in a

computerized model. Cognitive computing involves self-learning systems that

use data mining, pattern recognition and natural language processing to mimic the

way the human brain works. The goal of cognitive computing is to

create automated systems that are capable of solving problems without requiring

human assistance.


Big Data

Big data is data sets that are so voluminous

and complex that traditional data-

processing application software are

inadequate to deal with them. Big data

challenges include capturing data, data

storage, data analysis, search,

sharing, transfer, visualization, querying,

updating, information privacy and data source.

There are a number of concepts associated

with big data: originally there were 3

concepts volume, variety, velocity. Other

concepts later attributed with big data

are veracity (i.e., how much noise is in the

data) and value.

Documents

Kuliah Kapita Selekta Teknik Elektro Institut Teknologi Indonesia … · 2020. 7. 5. · Pengenalan umum mengenai sistem otomasi industri terkait sistem instrumentasi, kontrol dan